Sock-Like Footwear With A Padded Sole And Method For Making The Same

ABSTRACT

In the present invention relates to sock-like items of footwear commonly used in conjunction with outer articles of footwear such as shoes, boots and the like as an inner liner, in particular the liner is constructed with a durable padded sole, methods of constructing such liners are disclosed.

The present invention relates to substantially soft sock-like footwearcommonly used as an inner liner in conjunction with outer articles offootwear such as boots, shoes and the like.

Articles of footwear such as boots and shoes are typically constructedfrom a plurality of components the components are assembled usingvarious techniques such as stitching, bonding and riveting amongstothers. Footwear is typically composed of an upper part, which providesaccess via an opening for a foot and a lower part the sole that providesa durable and resilient material to contact the ground, as a whole whenassembled together they create an internal volume to accommodate a foot.Such articles of footwear typically have a major outer surface and amajor inner surface. The opening or orifice that allows entry of a footinto the footwear's inner volume or cavity often incorporate fasteningdevices to constrict the said opening this substantially assists tosecure a foot within the article of footwear, devices such as laces,elastic, hook and loop fastenings, toggle clamps and the like aretypically employed. Upon the surface of the interior volume of thefootwear there is commonly affixed a permanent lining material this istypically attached or laminated to the components or materials that area part of the outer surface of the footwear prior to the assembly of thefootwear. The composition of such inner linings can be specified toenhance performance and impart properties such as strength, stiffness,ventilation, insulation, bacterial control, permeability and comfort tothe footwear and other properties. Articles of footwear with prioraffixed linings that are assembled from two or more components whichinclude such pre-laminated materials and comprise of interfaces orjoints where the various components are joined the joints needadditional attention during the assembly of the footwear so that ifrequired the joint is water proof or resistant. Such additionalprocesses are time consuming and difficult to rectify after an item offootwear is fully assembled. Typically articles of footwear withpre-affixed linings are often specified and constructed for particularenvironments and uses and as by way of a simple example; thespecification of a material for a walking boot for use in a hotenvironment would be a thinner and lighter material than that used for asimilar boot specified for use in cold environments. Therefore a bootintended for a desert climate would therefore not perform well in anartic climate and visa versa for a boot intended for a cold climate.

By way of an alternative method of construction some articles offootwear are fabricated with a sock-like internal liner commonlyreferred to as a ‘bootie’ or ‘inner boot’. Such bootie's can beremovably affixed or positioned or alternatively permanently affixed tothe internal surface of the outer article of footwear. Advantages offootwear utilizing such a dual construction where the inner liner isfabricated separately from the upper and sole (the footwear's outercomponents) are numerous and varied and include the ability to adapt theproperties and performance of the footwear article as a whole such aswhen one bootie is removed and replaced from inside an outer boot orshoe with a different second bootie where the second bootie has beenmanufactured to an alternative specification than the first. Furtheradvantages include, footwear articles with such a dual construction canbe dried if wet or damp more effectively and cleaned more efficientlywhen the booties are manufactured to be detachable from within the outerboot or shoe. Additionally it is complicated to construct the many partsthat make up the uppers and sole (outer components) of shoes, boots andthe like and consistently manufacture them to be water proof or waterresistant if they are required to be and to keep the wearers feet dry inwet conditions. Shoes, boots and the like that are claimed to be waterproof or water resistant and are not and leak allowing water into thefootwear during use are the source of many returned footwear articles tothe manufacturers. It is a far simpler and a better economic solution tomanufacture the inner bootie to be water proof or water resistant thanthe whole of the footwear's outer, it is also simpler to test this innercomponent for its integrity prior to it's final assembly inside thefootwear that will incorporate such a bootie. A further advantage tosuch a construction is that the shaped polymer padding on the sole ofthe bootie can reduce the specification of the outer item's of footwearinsole or footbeds and in some footwear even replace the them.

It is known from prior art that various embodiments of bootie's existthe following documents generally disclose novel features, constructionsor specific applications for articles of footwear that utilise an innerliner such as a bootie.

Prior art of particular relevance includes; U.S. Pat. No. 4,599,810 toGuillaume, WO02080720 to Sheets & Finney, U.S. Pat. No. 5,526,584 toBleimofer & Danielax, WO9619127 to Herbert, EP0976337 to Labarre. Thesedocuments are applicable to booties but generally do not disclose novelmethods of fabricating the said booties.

Prior art, WO9851177, WO0232246 both to Polegato and U.S. Pat. No.5,588,226 to Schenkel, these documents describe various constructions ofsoles and mid soles that are perforated and configured to allow thepassage of gases but not liquids (particularly water) through theperforated holes, and refer to outer components of footwear not innerbootie liners. Prior art; ES2024806 to Jellici, U.S. Pat. No. 4,454,619to Bichet, U.S. 4,761,845 to Funck, EP0730833 to Delique, FR2614768 toLassade. These documents generally disclose devices for holding,pressing and bonding articles of footwear during their fabricationprimarily employing an elastic membrane to exert pressure upon thecomponents during their construction.

According to the present invention there is described a sock-like innerliner with shaped padding attached substantially to the sole portion ofthe inner liner, methods of constructing such a sock-like inner liner asto be used in conjunction with outer articles of footwear, such asboots, shoes and the like where the liner can be removably affixedinside the outer article of footwear or alternatively permanentlyaffixed to the inside of outer article of footwear. More specificallythe invention discloses a method to over mould integral comfort paddingwith a durable outer surface to the bootie. Where the padding issubstantially attached to the bottom or the sole of the liner. Where thepadding is substantially attached to the bottom or sole of the liner andcontinues around the sides of the bootie. Where the padding issubstantially attached to the bottom or sole of the liner and continuesaround the sides of the bootie more so at the toe and the heal portionsof the bootie. Where such padding is three-dimensionally formed andbonded to the liner in an operation using an elastic membrane to exertcontrolled pressure and transfer controlled heat to the padding andliner simultaneously. During the process the padding is selectivelyconsolidated in specific locations and formed to a predetermined shapeso that its outer surface can intimately fit inside other articles offootwear (if so required). Where the padding is shaped and consolidatedmore around the sides of the liner than on the bottom of the liner sothat around the sides of the booties the padding is less thick that onthe bottom. In an alternative embodiment where such padding isthree-dimensionally formed and bonded to the liner in an operationwhereby a heated polymer material is injected under pressure into acavity that incorporates a fabric liner while the sock-like liner issupported internally by a former, in particular the area of the bootieto where the padding is to be attached is enveloped by a tool thatcreates the said cavity the tool creates a seal around the periphery toretain the injected polymer within the cavity of the tool. Whereby thecavity imparts a predefined shape to the padding when the polymermaterial has cooled and or stabilized, the tool creating the cavity isremoved and the outer shape of the polymer padding reflects the internalshape of the cavity and is bonded to the sole or underside of thebootie. The formed over-moulded padding improves the wearer's comfortand the durability of the bootie.

The combined moulding and affixing of a pre-shaped or pre-formed polymercomponent to the sole of a fabric envelope utilizing heat and pressureexerted by a membrane is a low capital cost manufacturing solution forboth the plant and tooling. This manufacturing solution maintains highvolume production outputs but is also flexible and allows easycustomisation of the footwear items for both simple and sophisticatedproduct configurations. It also facilitates the technical advantage ofbeing able to selectively compress the perform polymer material this isimportant as the periphery of the padded sole can be consolidated sothat there is a smooth transition of the thickness of the padded polymersole when it is attached to the fabric envelope, from it's thickest onthe bottom of the footwear to it's thinnest at it's periphery thisimproves the footwears ergonomics and comfort as it is able to betterintimately fit inside outer items of footwear without causing localareas of high pressure to a wearer's foot.

A further advantage of this manufacturing method is that when thepolymer padding or pre-form component is consolidated the material isalso densified and it's durability and abrasion resistance issimultaneously enhanced this is an important feature particularly forthe areas that correspond or are adjacent to the back of the heal and abig toe's nail area of a wearer's foot.

Where an injection moulded manufacturing solution is employed a highlevel of automation is possible although plant and tooling costs arehigh and customisation is less flexible, very high production rates arepossible and there is less preparation of components required, howeverthis process has the disadvantage that it cannot consistently produce athin cross sectional moulded product which is essential to optimise thecomfort and ergonomics of this type of footwear product and preventblisters occurring. Additionally the integrity of the interface betweenthe fabric envelope and the polymer to the ingress of water throughcapillary action can be inconsistent particularly when bonding to a PTFEbased membrane film.

A brief description of the drawings

FIG. 1, shows in perspective a bootie with a shaped padded sole.

FIG. 2, shows a side view of a bootie with a shaped padded sole.

FIG. 3, shows a plan view of the major fabric components prior tofabrication used to assemble the bootie.

FIG. 4, shows a perspective view of an assembled bootie and insertcomponent and pre-form for the moulded sole prior to assembly with thebootie.

FIG. 5, shows a schematic drawing of the device and process.

FIG. 6, shows a partial section of the bootie on a last and beingcompressed by the membrane, shows method without pressure masking.

FIG. 7, shows a partial section of the bootie on a last being compressedby the membrane, shows method with pressure masking and showing a buttjoint.

FIG. 8, shows a perspective for an assembled bootie with a repeateddiamond pattern in three-dimensional relief upon the shaped padding withvent holes.

FIG. 9, shows a partial plan view for an optional pressure maskillustrating a three-dimensional relief where the circles representraised or lowered areas on a substantially planar plate.

FIG. 10, shows a partial section of the bootie on a last beingcompressed by the membrane, shows method with pressure masking andshowing a folded back lap joint.

Herein is described in detail the ‘bootie’ or ‘inner boot’ article offootwear and a method of manufacturing the same with reference to theaccompanying drawings.

The article of footwear is configured to cover the leg from anywherebetween the thigh to the ankle and or foot of the wearer/user and iscomposed of an upper portion (FIG. 1 a) where there is located anorifice (FIG. 1 c) through which a foot can be inserted and a lowerportion the sole (FIG. 1 b), so when top and bottom portions areconsidered as an assembled whole the two portions create an envelopewith an interior volume. Generally, the envelope is configured as anangled tube with an open end and a closed end where the closed end isformed to accommodate a wearers toes (FIG. 2 a) and the apex of theangle is formed to accommodate a wearer's heel (FIG. 2 b). The orificeis formed to accommodate a wearer's ankle or the circumference of a legat any point up to the thigh, e.g. the ankle, below the calf, the calf,above the calf, below the knee, the knee, above the knee, the thigh.Commonly the tubes opening may be configured with one or morelongitudinal cuts or slits extending partly towards the closed end ofthe tube, alternatively these can be configured as partial bellowsutilising folds instead of or including cuts, these are positioned toaid the entry of a foot by allowing the orifice to expand itscircumference. A method of constricting the opening such that can beachieved with elastic or cord when affixed around the circumference ofthe opening can be employed. Alternatively this may also be achieved byaffixing elastic or cord to both sides of one or more of thelongitudinal cuts or folds that aid the entry of a foot to constrict ortighten the opening after a foot has been inserted. Other suitablefastening devices may be employed such as hook and loop fastenings(Velcro, a trade name) press studs, zip fasteners and buttons amongstothers. Preferably the envelope is constructed from a plurality ofcomponent parts that are affixed substantially edge to edge bystitching, creating seams (FIGS. 4,d,e,f), this can be achieved byvarious methods such as bonding by heat; adhesive, radio frequencyvibrations, ultrasonic frequency vibrations, laser, taping and rivetingand by any other suitable bonding methods. In a preferred embodimentthere are two side components (FIGS. 3,a,b) and one bottom component(FIG. 3,c) joined by stitching at their peripheries and the seams tapedover to make the joints water tight (FIG. 1,d), where the tape materialis bonded by an adhesive that bonds and creates a water tight interface.In an alternative embodiment the envelope is constructed in a similarmanner as previously described however there are different permutationsof component parts that assemble to fabricate a similar sock-likeenvelope as described. In a further alternative embodiment of theinvention the envelope is constructed from a substantially tubularmonocoque structure such as formed when knitting a sock. In thepreferred embodiment of the invention the bootie envelope ismanufactured using substantially textile materials. The textiles orfabric materials are used individually in a single layer or incombination with other fabrics or textiles or polymer materials theseare typically laminated into composite structures wherein knitted, wovenor non-woven, materials are bonded in layers to themselves and othermaterials such as polymer films to produce hybrid fabrics with specificproperties. Generally such a laminate structure would comprise of aninner surface layer and a middle layer combined with an outer textileand/or polymer film layer (FIG. 10,b). Alternatively one-piece textilesmanufactured with a multi-layered structure can be employedindependently or in combination with other fabrics or polymer films. Inanother alternative embodiment a simpler textile structure would becomprised of two layers where a polymer film is laminated to one side ofa textile, this simple textile construction could be further enhancedwith an additional external layer of fabric laminated to the polymerfilm, this would enhance the abrasion properties of the polymer film.Typically the polymer film is itself a multi-layered structure withspecific engineered properties. In a preferred embodiment the polymerfilm is engineered to be impermeable to water and permeable to watervapour and other gases such as air. Therefore allowing a wearer's footto stay dry in wet conditions and yet still allowing the bootie envelopeto breath and transport water vapour through the film and preferablyaway from the wearer's foot. Between the laminations of the variousmaterials at the interfaces of the textile to textile structures andtextile to polymer films adhesive layers are often employed to bond thelaminations together, alternative bonding methods can also be employedbonding by heat, radio frequency vibrations, ultrasonic frequencyvibrations and others, however, preferably the method engaged does notsubstantially inhibit the precise porous properties of the laminatedcomposite textile, should it be desired. The afore mentionedcomposition's for the bootie's fabric envelope should not be consideredas limiting as there are many additional combinations of fabrics,materials and manufacturing methods that can be employed to construct asimilar component. Herein the words mandrel and last are to mean a footor foot-like or sock-like shaped structural support or jig, on or overwhich footwear components are positioned, assembled and supported whilemanufacturing processes are executed.

In a preferred embodiment of the invention the booties shaped paddingthat is positioned predominantly on the sole of the bootie (FIG. 1,b) iscomprised of a polymer pre-form (FIG. 4 a), this is a sheet material ofbetween 0.01 and 25 millimetres thickness. Preferably the pre-form hasbeen pre-coated with a re-activating adhesive on its inner surface (FIG.4 b, FIG. 6,c FIG. 7,c, FIG. 10,c) and then formed substantially to theshape of the booties sole in a primary moulding process, whereby theprocess substantially retains the integrity of the adhesive coating. Inan alternative embodiment the pre-form is an injection moulded polymercomponent. In a further alternative embodiment the pre-form is acompression moulded polymer component and in a further alternativeembodiment the pie-form is a thermoformed moulded polymer component. Themoulded perform component is preferably coated with an adhesive on itsinternal surface. Preferably the adhesive coating is a continuous andsubstantially constant deposit. Alternatively the adhesive isselectively applied in specific locations. The adhesive is applied witha coat weight of preferably not less than 10 and not more than 900 gramsper square metre, more specifically a coat weight of between 150 and 350grams per square metre is preferred with a softening temperature ofbetween 70° C. and 125° C. where the adhesive has a low viscosity at oraround 100° C.). Preferably a heat re-activating adhesive system isemployed, alternative adhesive systems can be employed and the adhesivecan also be applied to the pre-form component or the sole of the bootieor both. Preferably the pre-form is composed of a durable polymer suchas, EVA, EVA copolymers, TPU's, TPE's, TPR's, TPV's, EPDM's or otherelastomers with similar resilient and flexible properties. In analternative embodiment a vulcanising rubber material is employed, in afurther embodiment a partially cured or cured thermoset elastomericpolymer is employed such as a PU. The pre-form can be a solid or acellular material. In a preferred embodiment the structure of thepre-form material is substantially a cellular material and moreparticularly substantially a closed cell material structure. In afurther alternative of the preferred embodiment the structure of thepre-form material is substantially a cellular material and moreparticularly substantially an open cell material structure. Between theouter pre-form and the sole of the bootie envelope additional spacer orintermediate materials and structures can be optionally positioned suchas felts, open or closed cell materials waffle structures, gels,bladders, bellows and the like (FIG. 4,c, FIG. 7,g, FIG. 10,g) these arealternatively pre-laminated or combined to the textile component that isthe lower portion or sole of the envelope (FIG. 3,c, FIG. 6,h, FIG. 7,h,FIG. 10,h) the lamination can be prior to the components cutting out orjoining to the other components making up the booties envelope. Theintermediate materials can be made from materials that have a higherheat resistance, higher density, or lower density than the pre-formmaterial and possess alternative or improved properties than thepre-form material. These can be incorporated in specific locations onthe sole of the bootie to impart various and differing properties to thesole of the bootie than the pre-form could individually accomplish,properties such as ventilation, softness, firmness, ergonomic, fit,comfort, rebound, compression set, thermal regulation, thermalinsulation, anti-bacterial, fatigue, moisture wicking and others. Morespecifically and as by way of an example the sole directly under theheal area of a foot requires materials with improved compression set andimpact absorption properties than is generally required for theremainder of the sole. The pre-form can be a single component oralternatively produced from two or more components or sub-components orsub-assemblies that can be different materials, colours, thickness,shapes, texture or with different physical properties, such componentscan be positioned and placed together on the sole of the bootieenvelope. These can be collated on the sole of the bootie prior toexposing the bootie assembly to heat and pressure. In addition and oralternatively components may also be attached after the assembliesexposure to heat and pressure. The components can be placed andpositioned in a repeatable and consistent means by mechanical actuatorssuch as a robot arm controlled by an electronic programmable computertypically known as a pick and place robot, or manually by a humanoperator, or partly by both. To assist a manual placement of thecomponents onto the sole of the bootie envelope prior to the assembliesexposure to heat and pressure the location of the components can beindicated visually by projecting light in a predetermined patterncorresponding to the intended position/s of the component/s upon thesole of the booties fabric envelope, alternatively or in additiongraphic markings, textures, holes or other recognisable features on thecomponents can also aid alignment and registration of the componentparts during assembly.

In a preferred embodiment of the invention a method to securely affixthe pre-form, additional intermediate materials and components isdescribed in detail.

The pre-assembled bootie envelope is securely placed onto a closefitting foot shaped mandrel or last (FIG. 5,a, FIG. 6,a, FIG. 7,a, FIG.10,a) for support. The last/mandrel can be heated and cooled in acontrolled manner this is accomplished using hot air, hot liquids,electrical elements, infra-red radiation, steam, electro-magneticinduction and any other suitable methods this list should not beconsidered as limiting. The sole (FIG. 6,h, FIG. 7,h, FIG. 10,h) of thebootie envelope for convenience can be located facing upwardly toimprove visibility when positioning the shaped padding components orpre-form/s (FIG. 4,a FIG. 5,b FIG. 6,d FIG. 7,d, FIG. 10,d) onto thebootie envelope (FIG. 5,c FIG. 6,b FIGS. 7,b,h, FIGS. 10,b,h) that issupported internally by a last/mandrel. In an optional embodiment of theinvention adhesive is applied to the sole of the bootie envelope and/orone or more adhesive (FIG. 7,e FIG. 10,e) coated spacer/intermediate(FIG. 7,g FIG. 10,g) components are positioned in a repeatable fashiononto the bootie envelopes sole. The adhesive can be a liquid, paste filmor in any other suitable form capable to be utilized. The positioning ofthe intermediate components or sub-assemblies can be temporarily aidedby employing a pressure sensitive adhesive until securely bonded, thepre-form (FIG. 5,b FIG. 6,d FIG. 7,d, FIG. 10,d) is positioned over theintermediate components or sub-assemblies that are positioned on thesole of the booties envelope and the pre-form component/s is nowpositioned over the whole assembly with the intermediate component/ssandwiched between the pre-form and the bootie envelope any externalcomponents such as pre-printed graphics, labels or other shapedmaterials with specific advantageous properties are placed onto theouter surface of the assembly.

In a preferred embodiment of the invention the pre-form component/s ispositioned onto and over the sole of the bootie envelope with thepre-coated adhesive in near proximity to the envelopes surface, thesides of the pre-form extend around the sides of the bootie envelope andover the heel and toe areas of the envelope. More preferably thepre-form is configured to fully encompass the booties bottom seam (FIG.1,e FIG. 2,c FIG. 4,d FIG. 6,j FIG. 7,j FIG. 10,j) that is the joinbetween the component that is the lower portion of the envelope to theother constituent parts of the booties envelope. Encompassing this seamnegates the necessity to seal the seam with a waterproofing tape thisreduces the complexity and cost of fabricating the bootie simplifyingthe method of sewing the bootie bottom or sole component to the sidecomponents of the bootie as the bottom seam can be sewn from the outsideof the bootie and negates a sewing and sealing operation that had to bepreviously preformed with part of the sewing and/or sealing machineinside the bootie itself. The more complex sewing operation produces aseam whereby the edges of the bootie components are connected edge toedge (FIG. 7,j), a ‘butt joint’ with substantially no overlapping of thecomponents, a time consuming operation when compared to the simplifiedjoining technique where by the components are overlapped, a ‘lap joint’(FIG. 10,j) and joined by sewing this creates a lap joint or seam thatinitially protrudes outwardly from the external surface of the bootieand the protruding seam is then bonded to the side of the bootie (FIG.10,j) when the pre-form or padding is bonded to the bootie, with such aconstruction it is not desirable for the bootie to have protruding seamsor similar protrusions on or about the inside of the bootie as this canbe the source of discomfort to the wearer of such an article. Further,preferably as the pre-form is a non-permeable material and thereforewater-proofs the sole and sides of the bootie when securely attached tothe bootie envelope, the lower textile sole portion of the envelope canbe manufactured from a textile or other material without a breathablewater-proof polymer film laminated to it (FIG. 10,q), this furtherreduces the complexity and therefore the cost of fabricating the bootie.

The seam is pre-treated prior to the exposure of heat and pressure byapplying it with a chemical substance that aids its adhesion to thepre-form component and also assists the seam to be water proofed orwater resistant. Preferably the lower textile sole portion of theenvelope is manufactured from a textile or other material that is airpermeable and compliments an intermediate material/structure or assemblythat aids, creates or improves air circulation inside the bootieenvelope when in use, where by the action of walking, running and thelike air is pumped or moved between the inside surface of the outer shoeor boot and the wearers foot, such as a substantially open cell foam canachieve when compressed an then allowed to recover and expand to itsformer shape. In such an arrangement more preferably air is alsoexhausted out of the shoe or boot and replenished with fresh air fromoutside the boot. In a further refinement of the embodiment the volumeof air that is replenished during each step is adjustable. Theintermediate component is a cellular structured material while the outerpre-form component is also cellular structured material that is asubstantially a higher density micro-cellular foam (between 80 kg/m3 and300 kg/m3) and or a solid elastomeric material.

In an alternative embodiment the pre-form component is bonded to thebootie envelope on and around the sole of the bootie over the lower seamcreating a waterproof seal on or around the lower seam attachedexternally to the outer surface of the pre-form is a shaped pad. The pador padding in such an embodiment creates a cushion for the wearer's footand the pre-form component seals the bottom seam and provides acompatible and stable surface for the padding to be attached.

In such an assembly the pre-form can be a pre shaped polymer componentor a coated liquid or paste applied to the bootie by dipping, brush,spraying, extrusion or any other suitable means where the liquid orpaste subsequently solidifies to a resilient flexible material andcreates a waterproof seal to the bottom and the seam of the bootie, theshaped padding is applied by direct injection to the attached pre-formwithin a mould cavity, alternatively the padding is directly applied bycompression moulding to the attached pre-form or where the padding ispre-shaped by injection moulding, compression moulding, cutting,thermoforming or any other suitable means and post applied to thepre-form, a combination of one or more of the fabrication techniques canbe utilised simultaneously. The padding can be pre shaped and during itsapplication to the pre-form component it is further shaped whileadhering to the sole of the bootie such as is common with some types ofmoulded rubber soles for outer shoe or boot construction. In anotheralternative embodiment the pre-form is used as a medium to condition theinterface between the bottom of the bootie and the padding so that itsecurely adheres to and waterproofs the bottom of the bootiesimultaneously. The pre-form material and/or the padding material duringthe bonding process changes their physical properties for example thepre-form initially softens becoming less viscous and then solidifies,the padding materials molecules cross-link during the bonding process.In a further arrangement the pre-form is itself produced from a shapedhot melt adhesive or other substance with similar properties. Thepadding material can also be used as a spacer or support materialcreating distance between the sole of the outer boot or shoe and thewearer's foot. The padding, intermediate components or spacer materialsutilised in any of the disclosed embodiments is a thermoplastic polymer,or a thermoset polymer or a vulcanising rubber or any other suitablematerials such as cork, felts, fabrics, card and the like. In a furtheralternative embodiment the pre-form is bonded directly to the bootieenvelope on and around the sole of the bootie encompassing the lowerseam creating a waterproof seal this is achieved by directly injectingvia an injection moulding device a polymer material, such as EVA, TPU,TPE, TPV, PU, and any other suitable elastomeric polymers and polymercompounds, and/or a reaction injection moulding (RIM) device, (commonlyused to process two component PU polymers) with such devices mouldswould be employed to define the shape of the padding. In any of thedisclosed embodiments the bootie and/or the pre-form can be pre-treatedwith an adhesion/sealing promoting agent.

In a further improvement to the embodiments herein described, as a meansof providing enhanced ventilation around a wearer's foot, morespecifically as a means of providing improved ventilation between theinside surface of the outer shoe or boot and enhancing the ventilationaround a wearers foot. In particular the improvement provides superiorair circulation to the sole of the wearer's foot and therefore impartsgreater comfort by more efficiently regulating the temperature andhumidity while a user is wearing items of footwear that incorporates aherein described inner bootie. To facilitate increased ventilation theflow of air other gases and or vapours is permitted through the bottomor sole of the bootie through both the fabric envelope materials and theattached padding. Gases and vapours are allowed to travel to and or fromthe internal volume of the bootie to the interface between the outsidesurface of the bootie and the inside surface of the interior volume ofthe outer item of footwear. Groves, recesses, textures, raised and orlowered relief's or contours on any of the said surfaces will createpassages aiding and increasing the volume of gases and or vapours thatcan flow (FIG. 8,b). This can be accomplished through moulding, forming,embossing, cutting, etching, attaching, lamination, fabric textures andthrough the internal spaces of fabrics and fibres also any othertechniques that will create similar routes for the flow of gases and orvapours where the outer footwear and the inner bootie are in closeproximity to each other. The booties fabric envelope can be manufacturedfrom a significantly porous or permeable material that allows the flowof gases, vapours and liquids and small particulates through itsstructure and is substantially not water proof or water resistant,alternatively the booties fabric envelope can be manufactured frommaterials that are significantly permeable to only gases and vapours andis substantially water proof or water resistant. The polymer padding issubstantially a non-permeable or porous material. The polymer paddingattached to the sole or bottom of the bootie's fabric envelope istherefore configured with one or more holes or perforations (FIG. 8,c)through it's structure from one of the major surfaces through to theother of the major surfaces (FIG. 4,g). The holes permit the passage ofgases and vapours through the fabric of the bootie's envelope and thepolymer padding. When constructing a bootie that is intended to besubstantially water proof or water resistant yet permeable to gases andvapours the holes or perforations are located so that they are not inclose proximity to the perimeter or edge of the polymer padding and thatthey are also not in close proximity to the underlying seam or joints ofthe booties fabric envelope so that the waterproofness or waterresistant integrity of the bootie is not compromised. This isparticularly important when the affixing of the polymer padding is alsointended to act as a seal for the seam so that taping the seam with awater sealing tape is unnecessary. The holes or perforations in thepolymer padding would also remove any adhesive coating so that theadhesive cannot interfere with the flow of gases and vapours. Theperiphery of the holes or perforations are securely bonded and sealed tothe booties fabric envelope. Additional components that are a part ofthe padded sole and that are positioned between the fabric envelope andthe perforated polymer padding also are configured to permit the flow ofgases and vapours (FIG. 4,h) the insert or intermediate components willbe an open cell structure or porous material or shall be configured withsimilar holes or perforations as the polymer padding component and witha corresponding spatial relationship (FIGS. 4,h,g). Similarly,additional components that that are a part of the padded sole and thatare positioned on the outer surface of the perforated polymer paddingthese components also are configured to permit the flow of gases andvapours the insert or intermediate components will be an open cellstructure or porous material or shall be configured with similar holesor perforations as the polymer padding component and with acorresponding spatial relationship. It is preferred that parts of thepadded sole that have been configured with holes or perforations thatthe holes and or perforations of the different components aresubstantially registered and aligned with one another (FIG. 7,o FIG.10,o) so that different components that are part of the affixed polymersole allow an optimised flow of gases and vapours. Where there is morethan one component to collate for the pre-form/padded polymer sole theregistration of such holes and perforations during the assembly of thepadded sole components is achieved manually by visual alignment and orby use of a device that registers the holes, such as by protrusions thatlocate into the holes or perforations of the components and align theholes (FIG. 7,p FIG. 10,p), one or more protrusions that are supportedin spatial a relationship that corresponds to the spatial positioning ofthe holes or perforations in the components that are to be aligned sucha device is commonly referred to as a jig. During the application ofcombined heat and pressure via an elastic membrane to bond and form thepolymer padding to the sole of the fabric envelope a device referred toherein as a pressure mask is employed this device selectivelydistributes the pressure exerted by the membrane onto the polymerpadding components in a controlled and repeatable manner. During thebonding and forming process to stabilise the padding component/s and toprevent the vent holes from deforming and sealing the protrusions usedto align the holes and perforation are supported by the pressure maskingdevice therefore the pressure masking device and the padding locationjig are then a combined device (FIGS. 7 m,n,p FIGS. 10 m,n,p).

The holes and perforations are positioned on the components that arepart of the padded sole so that when the holes are aligned the separatecomponents are simultaneously aligned in their correct spatialrelationship to each other.

Generally, a device that utilises a pressure difference on opposingsides of a substantially planar elastic membrane with two major surfacesin combination with pressurised or evacuated chamber/s (FIGS. 5,g,h) iscommonly referred to as a membrane press, typically in operation suchpresses exert or apply substantially equal and even pressure across thearea of the membranes (FIG. 5,e FIG. 6,e FIG. 7,i FIG. 10,i) majorsurfaces. Additionally with such devices the forces exerted or appliedby the membrane onto the item/s being compressed are substantiallyperpendicular to the major surfaces of the membrane and/or item beingcompressed. This combined with the elastic properties of the membranefacilitates the wrap-round (FIG. 5,i) compression and moulding ofthree-dimensional shapes. Typically materials to be shaped by such amethod are semi-finished materials in the form of films or sheets (as isthe pre-form component). The process inherently forms materials intoshapes that reflect the underlying surface or shape that the material isformed over. A characteristic of this method of shaping materials isthat when the materials thickness is increased the outer shape of theformed material resembles less and less the object it is formed over,the surface form of the material shaped by intimate contact with themembrane becomes amorphous and generalised in shape, particularly whenthe material is simultaneously softened by heat as it is compressed bythe membrane. A further characteristic of this method of shapingmaterials is that the pressure applied by the membrane is substantiallyuniform across its area, the resultant cross sectional thickness (FIG.6,d) of a formed material remains substantially uniform, although sharpor angled edges will be rounded (FIG. 6,l FIG. 7,l FIG. 10,l) duringforming. Materials that have an internal cellular structure when heatedand softened are then compressed by a membrane press that can deform anddamage the cell structure with a subsequent loss of the cellularmaterials properties.

In a preferred embodiment of the invention the membrane press produces adefined outer surface (FIG. 8,a) to the pre-form and selectively (FIG.7,k FIG. 10,k) compresses and consolidates and densities the structureof the booties padded sole by using three-dimensional relief's andtextures, something that a conventional membrane press cannot achieve.The moulded definition is achieved by utilising a substantially planar(FIG. 5,j FIG. 7,m FIG. 9 FIG. 10,m) but three-dimensional semi-rigid orrigid support positioned onto the outer surface of the pre-form prior toforming with the membrane this serves to selectively reduce or mask thepressure exerted upon the pre-form by the elastic membrane inpredetermined areas and in a repeatable manner. It also increase's thepressure exerted upon the pre-form in predetermined areas and in arepeatable manner. This is achieved with a mesh like structure orperforated plates or with a plate with raised and/or lowered portions(FIG. 9,a FIG. 7,n FIG. 10,n) upon its surface, the plates are shapedsubstantially to a similar shape as the booties sole. Where a mesh or aperforated plate is employed the elasticity of the membrane used isinsufficient to deform fully under pressure into the holes of theperforated plate or mesh therefore these areas apply less pressure tothe pre-form and bootie assembly the than the perforated plate or meshwhich apply corresponding higher pressures. Where a plate with raisedportions is employed the elevated areas on the surface of the plate areused to space the plate away from the pre-form, the highest pressuresapplied to the pre-form during the over moulding process correspond tothe elevated areas on the plate and the lowest pressure appliedcorresponds with the non-elevated areas of the plate, similarly theelevated areas of a plate can be represented by the plate itself andholes in the plate can represent the non-elevated area's. These platesform defined shapes, patterns, relief's, textures, troughs, rails,dimples, pimples and the like to the outer surface of the bootiespre-form sole imparting a repeatable defined surface (FIG. 8,a) wherethe cross sectional thickness of the padding is controlled by thecorresponding thickness of the perforated plate, mesh or the height ofthe elevated areas. The bootie assembly is moulded in three-dimensionsbetween the membrane and the mandrel the cross sectional thickness ofthe padding is variable and controlled by employing the spacer member,preferably the spacer member should transmit thermal energy quickly andefficiently to minimize the heating and cooling cycle of the process.The surface patterns can be configured to impart further advantages andenhancements to the bootie such as grip, improved ventilation, improvedabrasion characteristics, aesthetics, design options and others. Thepatterns can include text and graphics or company logos. The sole areaof the supporting mandrel can also be shaped with textures, graphics,relief's and ergonomic contours and the like, these will be mirroredupon the internal surface of the bootie after the over-moulding process.As a further advantage of this method of construction the internalcellular structure of padding material is selectively controlled,preventing the membrane in specific areas from over compressing thematerial while the material is heated to above its plastic softeningtemperature. Another advantage of this method of construction is thatthe components to be bonded are held securely in an intimaterelationship and in an evacuated atmospheric environment (partialvacuum), minimising the possibility of air entrapment between the bondedcomponents, therefore creating good adhesion and decreasing thepossibility of water permeability around the lower seam of the bootie.Without the pressure mask the membrane compresses indiscriminately andsubstantially equally across its surface and can destroy or alter thephysical properties that are needed in the original cellular material,the pressure mask (FIG. 5,j) prevents this. Additionally the internalsurface of the bootie is formed into an advantageous form, improving thefit, ergonomics, ventilation, and other properties of the bootie. In anoptional embodiment of the invention the elastic membrane used to exertor apply pressure during the bonding process is patterned with athree-dimensional relief and consequently has areas of correspondinghigher and lower rigidity dependent upon the depth or height of therelief and the thickness of the membrane in those areas. The thicker thearea of the membrane the more rigid at that location and the thinner themore elastic this is accomplished by texturing or patterning the surfaceof the membrane in contact with the pre-form. Alternatively stiffeningdevices can be positioned within and or upon the membrane.

In a preferred embodiment of the invention the assembly comprising ofthe last or mandrel, bootie envelope, adhesives, spacer materials,pre-form and a pressure mask is placed inside a vessel or chamber (FIGS.5,h,g) and a heat resistant elastic membrane (FIG. 5,e FIG. 6,e FIG.7,i, FIG. 10,i) such as silicone (or similar) is placed over theassembly and then sealed by the outer edge (FIG. 5,d) of the chamber.Pressure is exerted onto the assembly by the membrane and the assemblyof components is supported by the last. The pressure is applied bycreating an unequal pressure on one side of the membrane compared to theopposing side this is achieved by means of fluids or gases supplied intoa chamber or evacuated from a chamber (or both) by external meanstypically by such devices as a vacuum pump, compressor, hydraulic pumpand other suitable devices known to those experienced in the art. Whilethe membrane is compressing the assembly the mandrel or last and themembrane are heated (between 80° C. and 250° C.) and then cooled to atemperature where the pre-form materials are stable (typically a cycleof between 1 minute and 18 minutes). During the process the pre-form padis securely bonded to the sole of the liner and extends around thesides, heel and over the toe area of the bootie. To aid the formingprocess particularly around the toe and heal areas a tourniquet (FIG.5,f, FIG. 6,f, FIG. 7,f, FIG. 10,f) device helps to constrict themembrane in specific locations of the bootie therefore increasing thepressure or force applied to the assembly in specific locations inparticular the toe and heel areas. The method of controlled pressuremasking improves the fit of the bootie when inside an outer article offootwear by reducing the thickness of the over-moulding locally at thesides of the bootie and provides a smooth tapered transition of theover-mouldings thickness from its edge at the sides of the bootie to thearea typically under foot the sole (FIG. 6,l FIG. 7,l FIG. 10,l) whichis engineered to be thicker than the sides. The method of controllingthe pressure applied to the bootie sole assembly allows the advantageousproperties of cellular materials to remain substantially as originallymanufactured in selectable locations. In a preferred embodiment of theinvention the perform is a cellular thermoplastic polymer material thatduring the over moulding process a skin or layer of melted or solidifiedmaterial forms while in close proximity to the heated elastomericmembrane and/or the pressure mask this forms a durable outer surface onthe sole and sides of the three dimensionally formed sole that is betterable to resist abrasion than the cellular material of the pre-form couldachieve prior to the over moulding process.

1. A Footwear inner liner comprising: an upper portion with an openingthrough which a foot can be inserted and accommodates a wearer's ankleor leg and a lower portion the sole, the upper and lower portions form asock-like envelope with a closed end to accommodate a wearer's toes,comprised of a layered fabric composite material that is permeable togases and impermeable to water the envelope is constructed from aplurality of joined parts where tape is bonded over joints waterproofingthe joint, bonded to the said lower portion of the envelopes outersurface is a resilient elastomeric material providing waterproofing overthat which it encompasses, the elastomeric material is formed to apre-determined shape; characterised in that: the said elastomericmaterial is padding, the said padding extends around the sides of theinner liner including the toe and heal areas and is formed and bondedthree dimensionally to the said envelope in an ergonomically consideredshape, the periphery of the said padding material is reduced inthickness consolidated and densified, a tapered transition of thepadding materials thickness from the sole to its periphery is provided,the said padding comprises a consolidated and densified durable skin onits outer surface, the said padding comprises selectively consolidatedand densified locations forming defined shaping of the padding.
 2. Afootwear liner as claimed in claim 1, wherein the bottom joint or seamof the sock-like envelope is sealed and waterproofed by the encompassingpadding material and negates the application of a waterproofing tapeover the bottom seam.
 3. A footwear liner as claimed in claim 1, whereinthe said padding is perforated in defined locations and the holes createroutes permitting gases but not water to pass between the inside offootwear liner to the inside of the outer footwear.
 4. A footwear lineras claimed in claim 1, wherein between the padding and the sole of thebootie envelope intermediate materials and structures are optionallypositioned and bonded.
 5. A footwear liner as claimed in claim 4,wherein the intermediate component is configured with holes that arealigned in a corresponding spatial relationship to the holes in thepadding and are configured to permit the flow of gases.
 6. A footwearliner as claimed in claim 3, wherein the periphery of the holes orperforations are securely bonded and sealed to the envelope.
 7. Afootwear liner as claimed in claim 1, wherein the fabric bottom or solecomponent of the fabric sock-like envelope comprises a fabric materialis permeable to gases and water.
 8. A footwear liner as claimed in claim2, wherein the bottom fabric sole component of the sock-like fabricenvelope is joined to the other upper fabric components of the linerwith a lap joint or seam where the seam initially protrudes outwardlyfrom the external surface of the fabric envelope.
 9. A footwear liner asclaimed in claim 3, wherein the intermediate materials and structurescan comprise felts, open or closed cell materials waffle structures,gels, bladders, bellows and the like.
 10. A footwear liner as claimed inclaim 1, wherein the padding is a durable polymer such as EVA, EVAcopolymers, TPU's, TPE's, TPR's, TPV's, EPDM's, vulcanising rubbers,thermoset elastomer polymers or other materials with similar resilientand flexible properties.
 11. A method for making a footwear inner linerwhich comprises: an upper portion with an opening through which a footcan be inserted and accommodates a wearer's ankle or leg and a lowerportion the sole, the upper and lower portions form a sock-like envelopewith a closed end to accommodate a wearer's toes, comprised of a layeredfabric composite material that is permeable to gases and impermeable towater the envelope is constructed from a plurality of joined parts wheretape is bonded over joints waterproofing the joint, bonded to the saidlower portion of the envelopes outer surface is a resilient elastomericmaterial providing waterproofing over that which it encompasses this isformed to a pre-determined shape, the said elastomeric material ispadding, the said padding extends around the sides of the inner linerincluding the toe and heal areas and is formed and bonded threedimensionally to the said envelope in an ergonomically considered shape,the periphery of the said padding material is reduced in thickness andconsolidated and densified, a tapered transition of the paddingmaterials thickness from the sole to its periphery is provided, the saidcomprises a consolidated and densified durable skin on its outersurface, the said padding comprises selectively consolidated anddensified locations forming shaping of the padding.
 12. A method formaking a footwear inner liner as claimed in claim 11, wherein thepadding is bonded using a heat activating adhesive.
 13. A method formaking a footwear inner liner as claimed in claim 11, wherein thepadding is three-dimensionally formed and bonded simultaneously to thesock-like envelope using a heat resistant elastic membrane to exertcontrolled pressure and transfer controlled heat to the padding andenvelope.
 14. A method for making a footwear inner liner as claimed inclaim 11, wherein the inner liner components are collated and assembledand supported upon and over a last that can be heated and cooled in acontrolled manner.
 15. A method for making a footwear inner liner asclaimed in claim 11, comprising a process of effecting selectedconsolidation and densification of the padding by positioning asubstantially planner, but three dimensional, support or pressure maskonto the outer surface of the padding to selectively reduce andselectively increase the pressure exerted upon the padding inpredetermined areas in repeatable manner.
 16. A method for making afootwear inner liner as claimed in claim 15, whereby the elasticmembrane is compresses the assembly the last and the membrane are heatedbetween 80° C. and 250° C. and then cooled to a temperature where thethen assembled footwear liner is stable.
 17. A method for making afootwear inner liner as claimed in claim 11, whereby an assemblycomprising of the pre-assembled envelope securely placed over the last,the optional intermediate materials and the padding positioned over andonto the envelope supported by the last a pressure mask is placed uponthe outer surface of the padding and when the assembly is inside avessel or chamber and a heat resistant elastic membrane such as siliconeor similar is placed over the assembly and then sealed by the outer edgeof the chamber, pressure is then exerted onto the assembly by themembrane and the assembly of the footwear liner components are supportedby the last by being positioned on and over the last, the pressure isapplied by creating an unequal pressure on one side of the membranecompared to the opposing side this is achieved by means of fluids orgases supplied into a chamber or evacuated from a chamber or both byexternal means both the last and the elastic membrane are heated andcooled during the process, such a device is commonly known as a heatedmembrane press.
 18. A method for making a footwear inner liner asclaimed in claim 11, whereby the padding is shaped in a primary formingprocess prior to it's placement upon the envelope.
 19. A method formaking a footwear inner liner as claimed in claim 19, whereby thepressure mask serves to selectively reduce or selectively increase thepressure exerted by the elastic membrane upon the assembly ofcomponents.
 20. A method for making a footwear inner liner as claimed inclaim 11, whereby the assembly of components to be bonded and formed areheld securely in an intimate relationship and in an evacuatedatmospheric environment or partial vacuum, minimising air entrapmentbetween the bonded components, creating good adhesion and decreasing thepossibility of water permeability of joints encompassed by the padding.